Cleaning device and methods of manufacturing thereof
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Solution Overview
Problem
Melamine-based cleaning sponges have a low strength when exposed to water, leading to rapid degradation due to dissolution and mechanical stresses, resulting in short service lifetimes, and previous solutions either fail to address mechanical impact or reduce effective cleaning properties.
Innovation Solution
A three-layer sponge design with a melamine core, a flexible polyurethane-based work layer, and a moisturizing layer, where the work layer's pores are larger than the melamine core's pores, allowing effective surfactant distribution and reducing mechanical stress on the melamine, while the moisturizing layer hydrates the melamine core and acts as a heavy-duty work layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fabric sack is used to enclose the melamine, then mechanical impact protection is improved, but abrasion from rubbing against the sack causes melamine degradation
Solution Approach 1:
The patent uses a flexible foam layer with larger pores than the melamine core to enclose and protect the melamine. This flexible shell provides mechanical impact protection while allowing the melamine to expand and contract without rubbing against a rigid fabric sack, thereby preventing abrasion-induced degradation.
2Strength
If two layers of polyurethane foam are glued onto either side of the melamine, then mechanical impact protection is improved, but the detergent solution remains inside the sponge and does not reach external surfaces
Solution Approach 1:
The patent applies local quality by creating a gradient in pore sizes across the sponge structure. The melamine core has small pores for detergent generation, while the outer foam layer has larger pores that facilitate detergent solution flow to the external surfaces. This localized differentiation of pore sizes ensures both mechanical protection and effective cleaning action.
3Ease of operation
If the sponge is made entirely of melamine, then cleaning properties are improved, but the service lifetime is reduced due to rapid dissolution and mechanical stress
Solution Approach 1:
The patent creates a composite structure combining melamine with a foam material (polyurethane or rubber foam). The melamine core provides superior cleaning properties through its detergent action, while the outer foam layer provides mechanical strength and durability. This composite material approach allows the sponge to maintain effective cleaning properties while significantly extending service lifetime.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design extends the sponge's service life by maintaining effective cleaning properties and reducing melamine degradation, allowing for efficient removal of contaminants without additional detergents and maintaining moisture for extended use.
Implementation Method 1
melamine dissolved in water is a highly effective surfactant which reduces the adhesion of contaminants to the substrate and emulsifies them
Implementation Method 2
melamine dissolved in water is a highly effective surfactant which reduces the adhesion of contaminants to the substrate and emulsifies them
Implementation Method 3
the pores in the work layer are connected to the pores in the melamine core; wherein a size of the pores in the work layer is at least 3 times and at most 20 times greater than a size of the pores in the melamine core
Data Source
AI summary
A cleaning sponge that efficiently utilizes melamine to effectively remove dirt and contaminants from a surface. The cleaning sponge includes a first sponge layer, a second sponge layer, a solidified detergent layer, a plurality of first pores, a plurality of second pores, and a plurality of third pores. The first sponge layer and the second sponge layer are connected to the solidified detergent layer on either side and provide protection for the solidified detergent layer against degradation. The plurality of first pores is distributed throughout the first sponge layer. The plurality of second pores is distributed throughout the second sponge layer. The plurality of third pores is distributed throughout the solidified detergent layer. The plurality of first pores and the plurality of second pores are in fluid communication with each other through the plurality of third pores. Water may flow through the cleaning sponge to create an effective surfactant.